Commissioning Motor Control Centers PDF

Engineering Encyclopedia
Saudi Aramco DeskTop Standards
Commissioning Motor Control Centers
Note: The source of the technical material in this volume is the Professional
Engineering Development Program (PEDP) of Engineering Services.
Warning: The material contained in this document was developed for Saudi
Aramco and is intended for the exclusive use of Saudi Aramco’s employees.
Any material contained in this document which is not already in the public
domain may not be copied, reproduced, sold, given, or disclosed to third
parties, or otherwise used in whole, or in part, without the written permission
of the Vice President, Engineering Services, Saudi Aramco.
Chapter : Electrical For additional information on this subject, contact

File Reference: EEX30204 W.A. Roussel on 874-6160
Engineering Encyclopedia Electrical
Content Page
INTRODUCTION................................................................................................................ 1
SAUDI ARAMCO REQUIREMENTS................................................................................. 2

Low Voltage ............................................................................................................. 2
Medium Voltage........................................................................................................ 4
EVALUATING MOTOR CONTROL CENTERS UPON RECEIPT.................................... 6
Visual Inspection....................................................................................................... 6
Verification Against Specification.............................................................................. 6
EVALUATING MOTOR CONTROL CENTER INSTALLATION AND TESTING........... 9
Visual Inspections ..................................................................................................... 9
Suitability .....................................................................................................10
Physical Damage...........................................................................................11
Alignment .....................................................................................................11
Cleanliness....................................................................................................11
Contactor/Controller Mechanism ..................................................................12
Lubrication ...................................................................................................12
Mechanical Inspections.............................................................................................12
Bolt Torque ..................................................................................................13
Open/Close Operation...................................................................................13
Main Contact Check .....................................................................................13
Door Operation ............................................................................................14
Electrical Inspections and Tests ................................................................................14
Point-to-Point Wiring ...................................................................................15
Megger.........................................................................................................15
Contact Resistance........................................................................................16
DC High-Pot ................................................................................................16

SYSTEM PRE-OPERATIONAL CHECK-OUT .................................................................18
SYSTEM OPERATIONAL CHECK-OUT..........................................................................19
WORK AID 1: REFERENCES FOR EVALUATING MOTOR

CONTROL CENTERS UPON RECEIPT..................................................20
Work Aid 1A: MCC Applications Checklist..............................................................20
Work Aid 1B: Low Voltage MCC Ratings ...............................................................20
Work Aid 1C: Low Voltage MCC Terminal Board Wiring .......................................21
Work Aid 1D: Minimum Low Voltage Indoor Motor Control Center
Technical Requirements.....................................................................22
Work Aid 1E: Medium Voltage MCC Ratings..........................................................32
Work Aid 1F: Medium Voltage MCC Requirements.................................................33
WORK AID 2: REFERENCES FOR EVALUATING MOTOR
CONTROL CENTER INSTALLATION AND TESTING.........................40
Work Aid 2A: MCC Commissioning Electrical Test Values......................................40
Work Aid 2B: Information, Formulas, and Tables for Use in Evaluating
the Results of Insulation Resistance (Megger) Tests ..........................41
Work Aid 2C: Information, Formulas, and Tables for Use in Evaluating
the Results of DC Hi-Pot Tests..........................................................42
Work Aid 2E: Excerpts from GI 2.710 .....................................................................50
GLOSSARY........................................................................................................................54

Table of Figures Page
Figure 1: Typical Low Voltage MCC ...................................................................... 4

Figure 4: Low Voltage MCC Terminal Board Wiring Type Features
(From NEMA ICS 2-322) .......................................................................21
(From NEMA ICS 2-322) (Cont'd) .........................................................22
Figure 5: Saudi Aramco Low Voltage MCC General Requirements
(From 16-SAMSS-503) ..........................................................................23
Figure 6: Saudi Aramco Low Voltage MCC Construction Requirements
(From 16-SAMSS-503) ..........................................................................24
(From 16-SAMSS-503) (Cont'd).............................................................25
Figure 7: Saudi Aramco Low Voltage MCC Enclosure and Isolating
Panel Requirements (From 16-SAMSS-503) ...........................................26
Figure 8: Saudi Aramco Low Voltage MCC Bus and Space Heater
Requirements (From 16-SAMSS-503) ....................................................27
Figure 8: Saudi Aramco Low Voltage MCC Bus and Space Heater
Requirements (From 16-SAMSS-503) (Cont'd).......................................28
Figure 9: Saudi Aramco Low Voltage MCC Nameplates, Wiring, and
Miscellaneous Equipment Requirements (From 16-SAMSS-503) ............29
Figure 9: Saudi Aramco Low Voltage MCC Nameplates, Wiring, and
Miscellaneous Equipment Requirements (From 16-SAMSS-503)
(Cont'd) ..................................................................................................30
Figure 10: Data Schedule for Low Voltage Switchracks and MCCs
(From 16-SAMSS-503) ..........................................................................31
Figure 11: Ratings for Class E2 (Fused) Medium Voltage Motor Controllers
(From SADP-P-116 and NEMA ICS 2-324) ...........................................32
Figure 12: Saudi Aramco Medium Voltage MCC General Requirements
(From 16-SAMSS-506) ..........................................................................33
Figure 13: Saudi Aramco Medium Voltage MCC Construction and Design
(From 16-SAMSS-506) ..........................................................................34
Figure 13: Saudi Aramco Medium Voltage MCC Construction and
Design Requirements (From 16-SAMSS-506) (Cont'd) ...........................35

Figure 14: Saudi Aramco Medium Voltage MCC Enclosure and

Isolating Panel Requirements (From 16-SAMSS-506).............................35
Figure 15: Saudi Aramco Medium Voltage MCC Bus and Space
Heater Requirements (From 16-SAMSS-506) .........................................36
Figure 16: Saudi Aramco Medium Voltage MCC Nameplates, Wiring, and
Miscellaneous Equipment Requirements (From 16-SAMSS-506) ............37
Figure 16: Saudi Aramco Medium Voltage MCC Nameplates,
Wiring, and Miscellaneous Equipment Requirements
(From 16-SAMSS-506) (Cont'd).............................................................38
Figure 16: Saudi Aramco Medium Voltage MCC Nameplates,
Wiring, and Miscellaneous Equipment Requirements
(From 16-SAMSS-506) (Cont'd).............................................................39
Figure 17: Dielectric Absorption Ratio Chart ...........................................................41
Figure 18: Example of DC Hi-Pot Test (Good and Bad Insulation) ..........................42
Figure 19: Saudi Aramco Pre-Commissioning Form, P-018,
Motor Control Centers............................................................................44
Motor Control Centers (Cont'd) ..............................................................45
Figure 20: GI 2.710 Excerpt ....................................................................................51
Figure 20: GI 2.710 Excerpt (Cont'd).......................................................................52
Figure 20: GI 2.710 Excerpt (Cont'd).......................................................................53

INTRODUCTION
Motor control centers (MCCs) are used when the centralized control of a number of motors is
possible and desired. MCCs function as a control location in which branch circuit incoming and
outgoing lines are marshalled. The modular designs of MCCs allow for convenient motor control
grouping that provides conservation of space and construction flexibility. Once the MCC for a
given installation is chosen, the MCC is ordered, shipped, received, inspected, installed, and tested
during the commissioning process. The commissioning process for MCCs in Saudi Aramco
facilities ensures that a safe and cost-effective system is installed that performs to the
specifications of the facility for the projected operating lifetime of the facility. Experience has
shown that the time and effort that is expended up front to ensure safety, quality control, and
adherence to Saudi Aramco and industry standards minimize subsequent equipment failure.
The MCC commissioning process involves evaluations, verifications, and checks that determine
whether the proper MCC specifications and installation requirements are met. Tests are also
performed to determine whether the electric power distribution system will operate properly and
safely after the MCC installation. When the MCC is inspected and tested satisfactorily during the
commissioning process, the system should operate in accordance with manufacturer's
specifications for its maximum useful life.
This Module provides information on the following topics that are pertinent to commissioning
motor control centers for Saudi Aramco installations:
• Saudi Aramco Requirements

• Evaluating Motor Control Centers Upon Receipt
• Evaluating Motor Control Center Installation and Testing
• System Pre-Operational Check-Out
• System Operational Check-Out
Saudi Aramco DeskTop Standards 1

SAUDI ARAMCO REQUIREMENTS
Large process and process support equipment relies on motors for primary and ancillary functions
throughout the manufacturing process (e.g., fans, circulation pumps, and blowers). The motor
power distribution, protection, and control equipment that is contained in an MCC are small but
important parts of the electric power system. It is usually advantageous to group motor
controllers at an MCC, which saves space, simplifies cabling, and frequently makes it possible to
install the control equipment in an air-conditioned room. For Saudi Aramco installations, it is
preferable to group controllers in a substation or control room instead of on switchracks that are
located in hazardous areas. An MCC provides centralized power distribution and control of a
group of motors. Centralized motor control eliminates
the need for trips to local control stations for equipment startups and shutdowns. Convenient
grouping of motor control circuits at an MCC also reduces the installation costs. Westinghouse,
Powell, and GE-type motor control centers utilizing Westinghouse and GE vacuum starters are an
example of some of the MCCs used in Saudi Aramco installations.
In Saudi Aramco installations, MCCs are grouped into two voltage levels: low voltage (0-600 V)
and medium voltage (2400 and 4160 V). This section of the Module contains information on
Saudi Aramco low and medium voltage MCC requirements.
Low Voltage
To commission low voltage MCCs, it is important for the commissioning engineer to be familiar
with the requirements for MCCs that are used in Saudi Aramco installations. This section will
briefly describe general Saudi Aramco low voltage MCC requirements. Due to the environmental
conditions in Saudi Aramco installations, the only outdoor low voltage MCCs that are allowed are
those MCCs that are of the switchrack construction. Specific Saudi Aramco low voltage MCC
requirements (e.g., enclosure and bus requirements) are provided in Work Aid 1.
NEMA ICS 2-322 classifies low voltage MCCs into the following two classes: Class I and Class
II. Class I MCCs consist of a group of combination starters or controllers that are operationally
independent. These starters or controllers do not include interlocking or control connections
between units. Class II MCCs consist of a group of combination starters or controllers that are
operationally related to each other for specific applications (e.g., sequence control). Class II
MCCs include interlocking and control wiring between units.

Class I or Class II low voltage MCCs that are used in Saudi Aramco installations must be rigid,
free-standing, metal-enclosed structures that are designed in accordance with NEMA Class I,
Type B. Figure 1 shows a typical low voltage MCC. Low voltage MCCs consist of vertical
sections that are assembled into a group. Because low voltage MCCs that are used in Saudi
Aramco installations must be suitable for back-to-wall or back-to-back mounting, they should
only contain front-mounted equipment (e.g., breakers, controllers, and switches). Each vertical
section grouping has a common power bus and that forms an enclosure to which additional
sections may readily be added. Each MCC vertical section is subdivided into compartments that
contain the various control and protective devices. Field rearrangement of MCC compartments
into any possible combination is accomplished through use of simple fasteners, such as bolts and
screws. The line side of MCC incomers must be provided with meters (e.g., ammeters and
voltmeters).
All control and protective devices that are installed in the MCC are selected so that they will
operate properly in the designated atmosphere without further protection. To prevent
overheating, MCCs are fitted with ventilation openings that are filtered or screened to prevent the
entrance of rodents and other foreign matter. Control device assemblies are arranged so the
assemblies can be removed for maintenance or repair without deenergizing the MCC (e.g., plug-in
line connections). Although fuses are an integral part of the control and protective device design
in most industrial installations, circuit breakers are preferred over fuses for Saudi Aramco
installations because of the inherent single-phasing characteristics of fuses. Saudi Aramco
practice does not normally include the use of capacitors that are directly connected to the
terminals of motors or motor control centers on low voltage systems.

Figure 1: Typical Low Voltage MCC
Medium Voltage
This section will briefly describe general Saudi Aramco medium voltage MCC requirements.
Specific Saudi Aramco medium voltage MCC requirements (e.g., construction and design
requirements) are provided in Work Aid 1.

NEMA Class E1 controllers and starters are not used in Saudi Aramco installations because of
their inherently low short-circuit interrupting ratings. NEMA Class E2 controllers are used for
medium voltage motors (2300 V and 4000 V motors) up through 1100 kW (4000 hp). Class E2
starters and controllers can be grouped to form motor control centers if the fault level does not
exceed the interrupting capacities that are listed in Figure 11 of Work Aid 1; however, controllers
should not be fabricated back-to-back or stacked over one-high. Two-high arrangements were
previously allowed; however, only one-high controllers are now allowed.
NEMA Class E2 controller fuses should be carefully chosen to ensure optimum coordination with
the overload relays and the relays of other breakers on the system. A static motor protection
(multi-function) relay that provides protection against single phasing should be specified and
implemented because NEMA standard ICS does not require the fuses to open all three phases. If
the fuses in all three phases do not open when a fault occurs, single phasing is possible.
In addition to the protection mentioned above, the medium voltage MCCs should include ground
fault relaying. A disconnect should also be provided for each starter as a means of isolating the
main contactor. Individual control power transformers must provide a source of control power
for each circuit within the MCC. Each motor control center bus must have a voltmeter with a
selector switch, and each incoming supply feeder must have an ammeter with a selector switch. A
circuit for motor space heating should be provided for each motor circuit that is powered from the
MCC. Each motor space heating circuit should have a separate molded case circuit breaker.
Additionally, the following items can also be accommodated in an MCC, if required:
• A starting reactor, or auto-transformer, that is used for control during reduced

voltage motor starting.
• A group surge protection device for the motor control bus.
• A test source of ac control power that is to be used during controller testing.
• A method for excitation control of synchronous motors. (Excitation control is
normally provided as a separate unit.)

EVALUATING MOTOR CONTROL CENTERS UPON RECEIPT
The installation of motor control centers (MCCs) is a process that occurs over a period of time.
MCCs usually supply power to the motors and pumps that form the base of the manufacturing or
refining process. The MCC installations begin with an identified need for pump and motor power
distribution and control centers in a new facility. After the facility design is approved, the MCCs
are ordered from the manufacturer. When the MCCs are received from the manufacturer, they
must be evaluated to ensure that they are proper for the installation. The purpose of the
evaluation is to verify that correct MCCs were received from the manufacturer and that the
proper equipment specifications and parameters were met. This section will describe how MCCs
are evaluated upon receipt.
Visual Inspection
When MCCs are received from the manufacturer, a visual inspection should be performed. The
purpose of the visual inspection is to verify that the MCC components (e.g., controllers and
indicating lights) that were received from the manufacturer are in good physical condition and that
all of the requested parts and accessories are present. Because damage can occur to the moving
parts associated with controllers installed in MCCs, only a cursory inspection is performed at the
receiving point. During the cursory inspection, the inspection personnel look for obvious
equipment damage and determine whether all necessary support equipment is present. A detailed
inspection of the MCCs is performed when they are completely installed at the site or facility.
Verification Against Specification
When a new facility or facility modification is at the equipment installation stage, the design of the
installation has already been completed. The type, the size, and the configuration of the MCC
that is selected for a specific power system should be shown in the drawings, the prints, or the
specifications for the installation. The purpose of verifying MCCs against the specifications is to
ensure that the equipment that is being installed meets Saudi Aramco and industry standards.
Generally, the verification against specifications consists of a determination of whether the type
and rating of the equipment that is to be installed match the size and type of the equipment that is
required for the installation. In some cases, this determination is accomplished by reading an
electrical plan that identifies the MCC type, the size, and the configuration.

During the verification against specifications, the Engineer inspects the manufacturer's nameplate
data on each MCC compartment and compares them to the requirements on the electrical plan to
determine whether the correct equipment is being used. In other situations, the Electrical
Engineer must rely on his knowledge of the correct application of MCCs to determine whether
the correct equipment is being used. The data sheets that were used to order the MCC from the
manufacturer should also be consulted. An example MCC data sheet is provided in Work Aid 1.
Any quality control, quality assurance, and test data that are provided with the MCC should also
be reviewed.
MCCs that are used in Saudi Aramco power systems should have a nameplate that is clearly
visible on the front of the MCC. The nameplate should contain manufacturer-type information.
The information that describes the MCC should consist of the manufacturer's name, the type
designation (if applicable), and the serial number. Because MCCs may contain different vertical
assembly compartments (e.g., controllers) that use control and indicating equipment at various
voltages, nameplates should be present at each MCC compartment. Electric power distribution
system MCCs are designed to operate at a specific frequency. Saudi Aramco electrical
distribution systems are designed to operate at 60 Hz. Medium voltage MCC controller ratings
should be in accordance with the table that is provided in Figure 11 of Work Aid 1.
Because there are different terminal board arrangements in low voltage MCCs, NEMA ICS 2-322
provides for the different types of terminal board wiring that are required in accordance with the
arrangement of the terminal boards. The different types of terminal board wiring are designated
Type A, Type B, and Type C. Low voltage MCC power and control leads should be arranged in
accordance with Type B. The features that are required by NEMA for Type A, Type B, and Type
C are provided in Work Aid 1.
MCC bus capacity should be computed through use of the normal full-load current of the largest
motor that is supplied by the MCC, all other motors that can be operated at the same time, other
loads supplied by the MCC, and future MCC load requirements. The incoming feeder of a low
voltage MCC should be provided with a switching device (unless a switching device is already
provided at the source of the incoming feeder and it is readily accessible). For low voltage
MCCs, the basis for computing the low voltage MCC bus capacity is provided in Work Aid 1.
The total MCC bus capacity should be less than the continuous current rating of the main
incoming circuit breaker or the fan-cooled current rating of the power source transformer
(whichever is most restrictive).

The low voltage MCC short-circuit rating should not be less than 105% of the maximum
available rms symmetrical current available at the MCC line terminals. The short-circuit
interrupting rating of the series combination of the MCC component (e.g., circuit breaker,
contactor, or thermal overload relay heaters) should be a minimum of 22,000 amperes rms
symmetrical. Short circuits are to be computed as the sum of the short-circuit current
contributions of the motors that are connected to the motor control center and all other
short-circuit current contributions of the supply system at the point of connection to the motor
control center.

EVALUATING MOTOR CONTROL CENTER INSTALLATION AND TESTING
MCCs are commissioned to verify that they have been electrically and mechanically assembled and
tested and that they conform to the specifications that are designated by the applicable Saudi
Aramco and industry standards.
Installation inspections are performed to verify that proper MCC installation materials are used,
that installation specifications and parameters are met, and that proper installation procedures are
followed. The installation inspection is conducted to ensure that MCCs will properly function
once they are installed. Electrical tests are performed to check the ability of MCCs to function
under all operating conditions and loads. Installation tests should detect shipping or installation
damage, gross manufacturing defects, or errors in workmanship or installation. Saudi Aramco
Pre-Commissioning Form P-018, Motor Control Centers, contains guidance on the items that
should be inspected, checked, and tested during the commissioning of MCC installations. Saudi
Aramco Pre-Commissioning Form P-018, Motor Control Centers, is provided in Work Aid 2.
The proper evaluation of inspection and testing data during the commissioning process can
maximize the operating time of equipment installations by providing a database for equipment that
can be used in the future for a determination of trends towards failure. Failure prediction can
drastically reduce equipment down-time; if a failure is predicted, operational changes can be
made, maintenance can be performed, or equipment that is failing can be replaced in a controlled
manner. If a problem is corrected before it causes damage, operating costs will be lower because
a malfunction can cause associated (or nearby) equipment damage and disruption of service, or
the problem can activate emergency repair crews. A failure in any one of the many inspections,
checks, or tests that are performed on MCCs during the installation and testing evaluation is
sufficient to prevent the MCC from being commissioned.
Visual Inspections
Visual inspections are used to assess the physical condition of MCCs. A visual inspection is a
pass/fail verification about a particular aspect of the physical condition or the operation of
equipment. Because the criteria that are established to determine the acceptability of the visual
inspections can be subjective, the visual inspections should be performed by an experienced
Electrical Engineer. Visual inspection items are listed in Saudi Aramco Pre-Commissioning Form
P-018, Motor Control Centers. Form P-018 is provided in Work Aid 2.

Because of the large number of inspection items that are associated with MCCs, several courses
of action are available for visual inspection failure. The course of action depends on the part of
the equipment that failed the visual inspection. A failure of indicating lights or switches can
generally be corrected through component replacement. For example, a failure of
contactor/controller mechanism inspection or cleanliness inspection can usually be corrected
through maintenance procedures. A physical damage or suitability inspection failure will probably
require the replacement of the damaged component. The following visual inspections are used to
assess the condition of MCCs in Saudi Aramco systems:
• Suitability
• Physical Damage
• Alignment
• Cleanliness
• Contactor/Controller Mechanism
• Lubrication
Suitability
The purpose of the suitability visual inspection is to determine whether the MCC and the
equipment that is contained in the MCC are appropriate for the application. Under normal
circumstances, the suitability of the equipment should be determined before the equipment is
placed into the system; however, a visual inspection should be performed to ensure that changes
that may have been made to the system have not exceeded the voltage and current ratings of the
circuit breakers, the contactors, and the fuses that are present in the MCC.
To determine the suitability of the MCC, a visual inspection of the nameplate data should be
performed and compared to the electrical system single line diagram. For example, if the
nameplate information on a controller does not match the ratings of the electrical system diagram,
the controller should be replaced with a controller that is correctly rated.

Physical Damage
Physical damage to the MCC or to that equipment that is contained in the MCC can lead to MCC
or controller failure during critical system operations. The magnitude of the electric energy that
passes through MCCs can propagate and amplify any minor installation damage. Damage to
MCCs can lead to catastrophic equipment failure, fire, personal injury, or death. Any physical
damage to MCCs that is noted requires the immediate replacement of the damaged component.
The most obvious and common forms of physical damage are cracks, dents, missing or broken
pieces, bent doors, and burned-out indicator lights. The purpose of the physical damage
inspection is to identify whether corrective maintenance or component replacement is necessary.
MCCs that show any form of physical damage, no matter how small, should be determined to
have failed the physical damage inspection.
Alignment
The purpose of the alignment inspection is to ensure that the MCCs will properly pass current
when they are installed in the electrical system between the power distribution cabinets and the
motor loads. Proper alignment of a controller draw-out cubicle frame will ensure that the
controller is properly connected to the system when it is installed in the MCC. Stab finger
tightness and alignment are also checked during the alignment visual inspection of MCCs.
Improper alignment can cause uneven component heating and wear. Due to the construction of
controller or contactor draw-out cubicle frames, frames that are out of alignment are usually
visually obvious.
Cleanliness
The purpose of the cleanliness visual inspection is to ensure the proper operation of the MCC
over the maximum operating life of the equipment. The accumulation of dirt over a period of
time will impede the proper operation of the equipment (e.g., controllers) that is contained in the
MCC and will reduce the dielectric strength of the MCC insulation. Dust and dirt can also reduce
the speed and sensitivity of a controller or contactor under fault conditions.
The accumulation of heavy amounts of dust and dirt should be cleaned away from the draw-out
cubicles and wireways of an MCC during maintenance cycles. MCCs that are installed in
extremely dirty, dusty, or humid areas may have to be cleaned more often than once during each
maintenance cycle.

Contactor/Controller Mechanism
The mechanism assembly of a contactor or controller that is contained in an MCC performs the
actual movement of the contacts to supply power to or to remove power from a motor or pump.
The purpose of the contactor/controller mechanism inspection is to ensure that moving parts in
the contactor/controller operate properly. Proper operation of the contactor/controller
mechanism will ensure that the MCC will supply the proper distribution and control for the
connected motor circuits. The inspector should visually determine that no obstructions exist that
will impede the movement of the contactor/controller mechanism.
Lubrication
The lubrication visual inspection should be performed in conjunction with the contactor/controller
mechanism visual inspection. The purpose of the lubrication visual inspection is to ensure that the
moving parts of the contactor/controller mechanisms are properly lubricated and free of rust.
Before the application of new lubrication can occur, hardened grease, dirt, and rust should be
removed from the surfaces that require lubrication. A cloth that is dampened with kerosene
should be used to remove the hardened grease and dirt. Care must be taken to ensure that the
cloth does not deposit fibers on the moving parts of contactor/controller. The deposit of cloth
fibers on the moving parts can cause subsequent improper mechanism operation. After the proper
preparation of the moving parts, a thin layer of lubrication should be applied. Excess lubrication
should be wiped off with a clean cloth.
Mechanical Inspections
A mechanical inspection is used to assess the ability of the MCC and the enclosed equipment to
physically perform the mechanical movements that are necessary for proper operation. Tests are
also performed during the mechanical inspection to assess MCC safety functions (e.g., breaker
trips). Mechanical inspection items are listed in Saudi Aramco Pre-Commissioning Form P-018,
Motor Control Centers. Form P-018 is provided in Work Aid 2. Because of the number of
mechanical inspection items that are associated with MCCs, there are several courses of action for
a mechanical inspection failure. The course of action depends on the part of the equipment that
failed the inspection. A failure of mechanism operation can usually be corrected through
maintenance procedures. For example, a bolt torque test failure can be corrected through
adjustment of the bolts with a torque wrench.

The following general mechanical inspections and tests are performed on MCCs that are installed
in Saudi Aramco systems:
• Bolt Torque
• Open/Close Operation
• Main Contact Check
• Door Operation
Bolt Torque
The purpose of a bolt torque inspection is to ensure that enough force is present to hold the
buswork and cubicle frames in place during normal controller or contactor operations and during
fault conditions. To determine the amount of force that exists at a bolt, a torque wrench is
applied to the bolt in the direction that will tighten the bolt, and the amount of torque is read.
Torque values for MCCs are provided in Saudi Aramco Pre-Commissioning Form P-018, Motor
Control Centers, that is provided in Work Aid 2. The manufacturer of the MCC will also provide
a list of acceptable torques in the MCC technical manual.
Open/Close Operation
Some MCC contactors or controllers in Saudi Aramco electrical systems can go for long periods
of time between operations. A contactor or controller must always be in a condition to operate
no matter how infrequently the motor or pump is being used. The purpose of the open/close
operation is to check the operation of the breakers and contactors to ensure the freedom of
movement of all moving parts. During opening and closing operations, the mechanical condition
of all auxiliary devices, bumpers, position indicators, latching, tripping, and operating mechanisms
is checked for proper operation.
Main Contact Check
A check of the main contacts is performed in conjunction with the open/close operation check.
The check of the main contacts consists of a pressure check, a contact alignment check, and a
check of the full contact area on contactors. The pressure check is performed to ensure that the
correct pressure is maintained at the main contact. The correct pressure at the main contacts is
necessary to provide a low resistance current path when the MCC is supplying power to a pump
or motor. The contact alignment and full contact area checks are performed to maximize the
contact surface area at the main contact face. Maximizing the contact surface will provide the
lowest resistance in the current path.

Door Operation
Each switchgear circuit breaker compartment must be provided with a door (safety barrier). The
door should be provided with a latch that completely closes the compartment when the controller
or contactor cubicle is completely installed or removed. The door should have a locking bar to
hold the door open. The door should also contain an interlock that prevents the closure of the
door unless the cubicle is completely installed or removed.
During the mechanical inspection, each cubicle compartment door operating mechanism should be
mechanically operated during the mechanical inspection, and the door interlocks (e.g., breaker
trips) should be tested.
Electrical Inspections and Tests
During the commissioning process, electrical inspections and tests are performed to check the
ability of MCCs to operate for a reasonable future period of time under all operating conditions
and loads. Acceptance or installation tests will usually detect shipping or installation damage and
gross defects or errors in workmanship in equipment construction. Once the installation and
inspection data have been recorded and assembled, a methodical and consistent program of
periodic data collection and evaluation should be established. As each new maintenance item,
test, splice, system addition, or system reconfiguration occurs, new inspections and data records
will be required and should be added to the existing data on file.
Because an electrical inspection or test failure can be caused by a design flaw, construction error,
equipment age, or operational misuse, some type of troubleshooting or maintenance activity
should be performed on the faulty equipment. For example, a contact resistance test failure can
be rectified by cleaning the contacts to remove carbon buildup or by replacing the contacts. Some
electrical inspection or test failures are not repairable, and they will require the replacement of the
equipment before the MCC can be commissioned. For example, an insulation resistance test
failure usually indicates a gross imperfection in the cable, the bus, or the circuit breaker insulation.
The following electrical inspections, checks, and tests are performed on MCCs:
• Point-to-Point Wiring
• Megger
• Contact Resistance
• DC High-Pot

Point-to-Point Wiring
Point-to-point wiring checks are performed to verify that MCCs comply with Saudi Aramco
wiring diagrams and manufacturer's specifications. Terminations and terminal blocks within the
MCC are also checked for routing and labeling. During the point-to-point wiring checks, control
and metering transformers and fuses (if they are present) are checked for proper application and
type. If necessary, adjustments are made to components such as relays, annunciators, alarms, and
targets.
Megger
The purpose of the insulation resistance megger test is to directly measure the insulation
resistance of the MCC and the components that are contained in the MCC. In the insulation
resistance test, the megger produces a voltage and measures the leakage current, which is
calibrated directly in second megohms. The voltage is applied, for example, between the breaker
phase and ground, or from phase to phase. The amount of leakage current that is detected results
in a meter readout of insulation resistance (in megohms).
To conduct the insulation resistance megger test, the megger is connected between each MCC
main bus phase ground and the megger is operated. Insulation resistance megger tests must be
conducted phase-to-phase and phase-to-ground on all panel buses, outgoing circuits, and PTs and
CTs that are contained in the MCC. The line side and the load side of each circuit breaker that is
installed in the MCC that is being commissioned must also be megger tested. Because the voltage
potentials that are generated during the megger test can damage any connected electronic
equipment, megger tests must not be performed on electronic equipment. The insulation
resistance values are recorded on a test data sheet or on Saudi Aramco Pre-Commissioning Form
P-018, Motor Control Centers, in the recorded test data section.
During the commissioning process, the Electrical Engineer should evaluate the insulation
resistance (megger) test values to ensure that the insulation resistance values that were recorded
are greater than the manufacturer's minimum value. If the manufacturer's minimum value is not
provided, the value of the insulation resistance should be greater than the rated voltage +1 kV in
megohms. For example, a 600 V rated system must have a measured insulation resistance that is
greater than 1.6 megohms. Any value of insulation resistance that is less than the minimum
specifications should be investigated by the Electrical Engineer who performs the test data
evaluation.
The ratio of two time-resistance readings (such as a 60-second reading that is divided by a 30-
second reading) is called a dielectric absorption ratio. The dielectric absorption ratio is useful in
recording information about the insulation. If the ratio is a ten-minute reading that is divided by a
one-minute reading, the value is called the polarization index.

Because constant cranking is required for hand-cranked megger instruments, it is easier to run the
test for only 60 seconds and take the first reading at 30 seconds. When a power-operated megger
instrument is used, the results of running the test for a full ten minutes and taking readings at one
and ten minutes will give the polarization index. An explanation of the evaluation of the dielectric
absorption ratio is provided in Work Aid 2.
Contact Resistance
The purpose of the MCC contact resistance test is to identify contacts that are defective or
detrimental to the operation of the circuit breakers, the contactors, or the starters or bus sections
that are contained in the MCC. The contact resistance test may also identify loose connections in
circuit breakers, contactors, starters, or bus sections. Circuit breakers, contactors, or starters
generally have removable cubicles or drawers to facilitate temporary removal for maintenance or
testing. Once the equipment is removed from the MCC and with the contacts of the equipment in
the closed position, the leads of a digital low-resistance ohmmeter are placed across the line and
load sides of the contacts and measurements are taken. A digital low-resistance ohmmeter can
deliver enough power to the contacts to make accurate readings that have more validity than
those readings that can be obtained through the use of an ordinary multimeter. The contact
resistance is recorded on a test data sheet or in the Saudi Aramco Pre-Commissioning Form, P-
018, Motor Control Centers.
Increased contact resistance may be caused by contacts that do not make proper contact or by
pitting on the surface of the contacts. The contact resistance values that are recorded should be
consistent with manufacturer's recommended values. Generally, values of contact resistance in
excess of 200 microohms and deviations of more than +/- 20% should be investigated. Technical
data to evaluate the results of the contact resistance test can be found in the circuit breaker
manufacturer's technical manual or in the Saudi Aramco Pre-Commissioning Form, P-000,
Testing Guide Lines.
DC High-Pot
The purpose of the dc high potential (high-pot) test is to identify internal faults in or damage to
the MCC bus insulation system. The dc high-pot test should be done prior to the initial
energization of the MCC and after the megohmmeter test. The dc high-pot testing technique for
MCCs involves the measurement of increased dc voltage that is applied to the system under test.
The value of the leakage current is tracked as the test voltage is increased through several steps
and becomes a criterion of the condition of the MCC insulation.
Electrical test reference information for the dc high-pot test is provided in Saudi Aramco Pre-
Commissioning Form, P-000, Testing Guide Lines. A portion of P-000 is provided in Work Aid
2. The electrical test reference information provides the recommended dc high-pot test procedure
and test voltages for the various connected equipment voltage ratings.

During the high-pot test, the leakage current is plotted against time at the end of each timing
interval. Figure 18 of Work Aid 2 illustrates representative current-time curves over a test period.
The curves in Figure 18 show that good insulation exhibits a steady decrease in leakage current
with time and that bad insulation exhibits a rise rather than a decline in leakage current. The
polarization index can be calculated from this test data through division of the leakage current
after one minute by the leakage current that is obtained after ten minutes.
The Electrical Engineer should evaluate the dc high-pot test leakage current test data to ensure
that the MCC high-pot test data meet the minimum requirements of a successful test. A
polarization index value of less than two or dc high-pot test data curves that indicate a steady
increase in leakage current over the duration of the test should be investigated by the Electrical
Engineer who performs the test data evaluation.

SYSTEM PRE-OPERATIONAL CHECK-OUT
The system pre-operational checkout phase of the commissioning cycle for MCCs provides an
opportunity for Saudi Aramco personnel to perform wiring checks, subsystem component check
outs, and MCC component interlock tests. Each MCC controller, contactor, or starter
component is checked to ensure that it works individually and as a complete system.
Subsystems are checked to ensure that electrical continuity exists for control and protective
devices. The proper operation of all subsystems is tested through use of controlled operation and
check out of the controls and protective devices. Each subsystem is performance tested through
the application of full operational voltage to each subsystem through the proper protective
devices. A complete operational test is performed on equipment controls, interlocks, protective
devices, and components with each subcircuit connected to its main system. During the
performance test, the main systems are still isolated and independent from plant systems. Before
the equipment is connected to the plant system, subsystem performance testing is critical to ensure
the proper and safe operation of the equipment protection and control subsystems.
Operation tests are performed to ensure that the various MCC operational interlocks function
properly. For example, if an MCC cubicle door has a circuit breaker trip interlock, the trip
interlock is tested. Circuit breaker trip tests are also conducted.

SYSTEM OPERATIONAL CHECK-OUT
The operational check-out phase of the commissioning cycle for MCCs provides an opportunity
for Saudi Aramco personnel to perform the following:
• Source feed compatibility checks

• Complete MCC functional test
Source feed compatibility checks are performed on MCCs through application of the full system
voltage onto the MCC with all components (e.g., controllers) installed. With the voltage applied,
voltage phasing, synchronizing, device rotation, protective relay calibration, and other source feed
compatibility checks are performed. Parallel or alternate power source feed operations are also
performed to ensure the total operation of the major components of the MCC.
A complete system functional test is performed on MCCs to ensure that the entire low-voltage
electric power distribution system functions in accordance with the system design. During the
complete system functional test of MCCs, the electric distribution system is allowed to assume a
fully loaded condition for a period of time that is adequate to obtain the maximum system
temperature. After the loaded time period, MCC temperatures are monitored. MCC
temperatures can be monitored locally through use of temperature monitoring equipment or
through use of thermographic surveys. Temperature monitoring equipment can be temporarily
installed at MCC vents or in the MCC itself. Particular attention should be paid to wiring and
terminal connections during the complete system functional test.

WORK AID 1: REFERENCES FOR EVALUATING MOTOR CONTROL CENTERS

UPON RECEIPT
Work Aid 1A: MCC Applications Checklist
MCC rating information can be found on the equipment nameplate or in the manufacturer's
technical manual. Use the following checklist and the appropriate sections of this Work Aid to
verify that the type, the rating, and the operational characteristics of MCCs are correct for the
application based on Saudi Aramco and industry standards.
• Verify that the MCC low or medium voltage nameplate ratings are correct for the
application.
• Verify that the low voltage MCC switchgear meets the Saudi Aramco requirements
that are shown in Figures 4 through 9.
• Verify that the low voltage MCC matches the information that is provided in the
data sheet (Figure 10).
• Verify that the medium voltage MCC switchgear meets the Saudi Aramco
requirements that are shown in Figures 11 through 16.
Work Aid 1B: Low Voltage MCC Ratings
This section of the Work Aid describes low voltage MCC ratings. For low voltage MCCs, the
MCC bus capacity should be computed on the following basis:
• 125% of the normal full-load current of the largest motor that is supplied by the
MCC, plus
• 100% of the full-load current of all other motors that can be operated at the same
time, plus
• 100% of all other loads (or a lower percentage if a diversity factor can be properly
applied), plus
• 20% allowance for future requirements.
The final MCC bus capacity must be at least equal to the lesser of:
• The continuous current rating of the main incoming circuit breaker.

• The fan-cooled current rating of the power source transformer.

The low voltage MCC short-circuit rating should not be less than 105% of the maximum
available rms symmetrical current available at the MCC line terminals.
The short-circuit interrupting rating must be a minimum of 22000 amperes of rms symmetrical
current. Short circuits are to be computed as the sum of the short-circuit current contributions of
the motors connected to the motor control center and all other short-circuit current contributions
of the supply system at the point of connection to the motor control center.
Work Aid 1C: Low Voltage MCC Terminal Board Wiring
Because there are different terminal board arrangements in MCCs, NEMA ICS 2-322 provides for
the different types of terminal board wiring that is required in accordance with the arrangement of
the terminal boards. The different types of terminal board wiring are designated Type A, Type B,
and Type C. The features that are required by NEMA ICS 2-322 for Type A, Type B, and Type
C terminal board wiring are shown in Figure 4.
Type A (a) Terminal boards for load or control connections are prohibited.
(Class I (b) Connection diagrams are used only for each combination controller or
Only) control assembly.
(c) Sketches of the overall dimensions of the control centers are required.
Type B (a) A unit control terminal board must be provided. Unit load terminal blocks
must also be provided for combination controllers that are Size 3 or smaller.
These terminal boards must be mounted on, or adjacent to, each unit.
(b) Sketches of the overall dimensions of the control centers are required.
(c) (Class I Only). Connection diagrams are used only for each combination
controller or control assembly.
(d) (Class II Only). The necessary interconnecting wiring between
combination controllers and control assemblies must be in the same MCC
section.
(e) (Class II Only). A connection diagram of the complete control assembly is
required.
Type C (a) Master section terminal boards must be present that include load terminals
for combination controllers that are Size 3 or smaller. All control terminals
for all combination controllers or control assemblies in each vertical section
must be mounted on the stationary structure. Load terminal boards for
feeder tap units are prohibited.

(From NEMA ICS 2-322)

Type C (b) Sketches of the overall dimensions of the control centers are required.
(Cont'd) (c) (Class I Only). Wiring between sections or between master terminals is
prohibited.
(d) (Class I Only). Interconnections between any combination controllers or
control assemblies are prohibited. All outgoing wires from any unit must be
carried to the master terminal board, except wiring for combination
controllers that are Size 4 or larger.
(e) (Class I Only). Connection diagrams for each combination controller or
control assembly are required.
(f) (Class I Only). A sketch of main terminal boards showing general location
of terminals is required.
(g) (Class II Only). The necessary interconnecting wiring between combination
controller and control assemblies must be in the same section.
(h) (Class II Only). A connection diagram of the complete control center is
required.

(From NEMA ICS 2-322) (Cont'd)
Work Aid 1D: Minimum Low Voltage Indoor Motor Control Center Technical
Requirements
The minimum technical requirements for low voltage indoor motor control centers (MCCs) are
defined in 16-SAMSS-503. Low voltage in Saudi Aramco installations is defined as 600 V and
below. The requirements of 16-SAMSS-503 apply to full-voltage combination starters, feeder
circuit breakers, contactors, dry-type transformers, panelboards, and auxiliary equipment that are
assembled into MCCs and switchracks; however, only the MCC information will be presented in
this section of the Work Aid.

Figure 5 shows Saudi Aramco low voltage indoor MCC general requirements from 16-SAMSS-
503.
General MCCs must be suitable for operation at nameplate rating within an ambient
Requirements air temperature range of 0 oC to 40 oC.
MCCs must conform to the requirements of NEMA ICS 2-322, except as
otherwise indicated in 16-SAMSS-503.
Designs and materials that are used in control assemblies must have at least
two years of verifiable proven field service. The Vendor must supply a
Users List indicating User company name, installation site, date of
installation, and equipment characteristics that are similar to the equipment
that is quoted.
Figure 5: Saudi Aramco Low Voltage MCC General Requirements

(From 16-SAMSS-503)

Figure 6 shows Saudi Aramco low voltage MCC construction requirements from 16-SAMSS-
503.
General An external indication (e.g., "ON" or "OFF") must be provided to show the
Construction circuit breaker or disconnect switch position.
Requirements
Motor control assemblies must be "fully-rated" for bracing and interruption
of the available short circuit current that is indicated on the Engineering
Drawings and/or the Data Schedule.
No operating device or instrument can be more than 1980 millimeters (78
inches) above the floor.
Motor data that is required for the selection of the controller and motor
control components must be as shown on the Engineering Drawings.
All devices that are supplied under this specification that are to be used in
hazardous (electrically classified) locations must be housed in enclosures
that are approved for the purpose. Arcing devices must be housed in
certified explosion proof enclosures. Sealing fittings must be furnished as
required.
Oil-immersed equipment (NEMA Type 8) is not acceptable.
Minimum MCCs must be rigid, free-standing, metal-enclosed structures, that consist
MCC of vertical sections assembled into a group that have a common power bus
Construction and that form an enclosure to which additional sections may readily be
and Design added.
Requirements Each MCC vertical section must be subdivided into compartments that
contain the various control and protective devices.
MCC cubicle design must be NEMA Class I, Type B.
All ventilation openings must be suitably filtered or screened with a
specified corrosion-resistant material (such as stainless steel hardware cloth
or galvanized screen) that is arranged to prevent the entrance of rodents and
other foreign matter.

(From 16-SAMSS-503)

Minimum All control devices must be selected for proper operation in the designated
MCC atmosphere without further protection.
Construction Structure drilling, tapping, cutting, welding, and forming must be designed
and Design and factory finished to permit field rearrangement of the controller
Requirements compartments into any possible combination by the use of simple fasteners
(Cont'd) such as bolts and screws.
If the bus plug-in contact design uses special shapes or fittings that are
connected permanently to the bus, the shapes or fittings must be provided at
all locations that are needed by any rearrangement of all possible size
compartments.
Control device assemblies must have plug-in line connections or must be
arranged so the assembly can be removed without deenergizing the MCC.
Fuses must be accessible for replacement without removing the control
device assembly from the MCC or disconnecting cables.
Units that are designated as "FUTURE" on the Engineering Drawings must
be complete with stationary elements, drawout pans, and door.
A means must be provided to cover the openings which expose the vertical
bus.
Adequate space must be provided for incoming power, control, ground
conductors, and conduit terminations. Minimum bending radius restrictions
must be followed. Provisions for terminating all incoming conductors must
be included.
The line side of incomers must be provided with an ammeter and voltmeter,
together with associated current and potential transformers.

(From 16-SAMSS-503) (Cont'd)

Figure 7 shows Saudi Aramco low voltage MCC enclosure and isolating panel requirements from
16-SAMSS-503.
MCC Enclosures must be suitable for back-to-wall or back-to-back mounting.

Enclosure Back-to-back constructions that have a common horizontal bus are not
Requirements acceptable.
Enclosures must be designed for front access only and must be provided
with floor channels.
Enclosures must have floor plates with holes and grommets as specified on
the Data Schedule. Holes must be provided with cover plates.
Vertical sections must have a minimum width and depth of 508 mm (20 in),
with each vertical section having a vertical wiring compartment with hinged
covers, means for support of wiring, and grommets where wiring penetrates
metal barriers.
Space for horizontal wiring between vertical sections at the top and bottom
must be provided. Wiring spaces must be isolated from the buses.
Minimum individual space allocation in vertical sections of motor starters
must be sufficient to accommodate a NEMA Size 2 controller.
All hardware must be galvanized cadmium or chromium-plated mild steel or
stainless steel.
Isolating Isolating panels must be provided between device, bus, and cable
panels compartments to permit the cables to be pulled safely into the MCC and
extend to device compartments with the control center energized.
Uninsulated live parts must not be located in cable pulling spaces.
Isolating panels must be provided between device, bus, and cable
compartment to permit personnel to work safely. Safe work is performed
within either an empty compartment or a compartment from which the
control assembly has been removed while the bus is energized.
The isolating panels must prevent transmission of arcs and must retard the
migration of arc products into bus spaces and/or cable pulling spaces.
The isolating panels must prevent transmission of arcs and retard the
migration of arc products between device compartments even when an
intervening device assembly has been removed.
Figure 7: Saudi Aramco Low Voltage MCC Enclosure

and Isolating Panel Requirements (From 16-SAMSS-503)

Figure 8 shows Saudi Aramco low voltage MCC bus and space heater requirements from 16-
SAMSS-503.
Bus Main horizontal buses must consist of electrical grade copper bus bars that
Requirements are mounted on glass-reinforced polyester or non- hygroscopic ceramic
insulators.
Buses must be rated for a minimum continuous current rating of 600 A,
braced for a minimum of 42,000 A symmetrical short circuit current.
All bus connections must be bolted with all bar connecting surfaces
silver-plated or tin-plated.
Power bus bars, bar connections and plug-in connection continuous current
ratings must be based on a 40 oC ambient temperature and 50 oC
temperature rise.
Bus phase arrangement must be 1- 2- 3, counting from front to back, top to
bottom, or left to right, as viewed from the front of the control assembly.
MCCs must have a silver plated or tin plated bolted copper bar ground bus
that is horizontally mounted near the bottom of the structure and that
extends throughout the length of the MCC.
Cable is not an acceptable substitute for bus material.
Connectors that are sized for 70 square millimeters (No. 2/0 American Wire
Gage (AWG)) copper grounding conductor must be provided on each end
of the bus.
The minimum momentary rating of all phase, neutral, and ground buses
must be 42,000 RMS symmetrical amperes.
The continuous current rating of neutral buses, where specified, must be 50
percent of the bus phase rating.
Figure 8: Saudi Aramco Low Voltage MCC Bus

and Space Heater Requirements (From 16-SAMSS-503)

Bus Vertical power buses must be copper, must have a minimum continuous
Requirements current rating of 600 A, and must be enclosed in a flame-retardant,
(Cont'd) non-tracking, low-hygroscopic, glass-reinforced, polyester insulation and
bus support system. The bus support system must provide phase-to-phase
and phase-to-ground bus isolation.
Cable is not acceptable as a substitute for copper bar, including the
transition busing to other equipment.
Space Heaters Space heaters must be provided in each MCC vertical section.
Space heater heating elements must have a voltage rating of approximately
twice the supply voltage.
Heaters and associated circuits must be rated for continuous duty.
A space heater control system must be furnished for each piece of vertical
equipment and must consist of a thermostat that is used to control the
heater so that the equipment interior temperature is maintained several
degrees above the ambient temperature.
The space heater system must be completely wired and must include a
manual disconnect.
Space heater sheath temperature for all equipment must be limited to the
temperature that is specified on the Data Schedule.
Figure 8: Saudi Aramco Low Voltage MCC Bus and

Space Heater Requirements (From 16-SAMSS-503) (Cont'd)

Figure 9 shows Saudi Aramco low voltage MCC nameplates, wiring, and miscellaneous
equipment requirements from 16-SAMSS-503.
Nameplates Engraved phenolic nameplates that show black letters on white face must be
provided and attached with stainless steel or brass screws to the door of
each MCC unit.
Warning nameplates must be provided on each compartment for which
opening of the branch circuit breaker does not de-energize all voltage
sources within the unit. The warning plate must have white characters on a
red background that read: "CAUTION - THIS UNIT CONTAINS AN
EXTERNAL VOLTAGE SOURCE!".
A nameplate must be attached to each controller and must indicate
manufacture's catalog designation, maximum horsepower rating at a
specified voltage, maximum continuous amperes, and control circuit
voltage.
All nameplate wording must be in the English language according to
American usage except for danger and warning indicators which must be
written in both Arabic (Naskh script) and English. White characters on a
red background must be used.
Separate nameplates, suitably located, must indicate the following:
1) Warning or operational instructions as required.

2) Identity of all relays, meters, etc.
3) Purchaser's assigned motor or equipment number and
identification, when specified.
The bus structure, each motor control unit, and each feeder tap unit must be
identified with its short-circuit current rating expressed in RMS symmetrical
amperes. This identification supersedes any interrupting rating shown on
fuses or circuit breakers that are included in the units.
Figure 9: Saudi Aramco Low Voltage MCC Nameplates, Wiring,

and Miscellaneous Equipment Requirements (From 16-SAMSS-503)

Wiring Control and secondary conductors must be stranded copper, 600 V, NEC
Type SIS or THHN. The minimum conductor size must be 2.5 square mm
(No. 14 AWG).
Insulated, ring tongue, compression (crimped) terminals must be provided
for all control and secondary wiring terminations.
All connection points between assembly control devices and field wiring
must be made with terminal blocks.
Terminal blocks must be one-piece, phenolic, barrier-type, rated 20 A, 600
V, minimum, with pre-numbered marking strips. A maximum of two wires
per point is permitted.
Two-piece terminal blocks which allow complete withdrawal of unit
assemblies are acceptable.
Shorting terminal blocks must be provided for current transformer circuits.
Each wire must be identified with a thermoplastic, slip-on type (ferrule),
marker with permanently printed characters. Snap-on or adhesive type
markers are prohibited.
Miscellaneous Pushbutton and selector switches must be of the heavy-duty oil-tight type
Equipment rated 10 A continuous at 600 V.
Indicating lights must be of the incandescent heavy-duty oil-tight type with
integral transformer or series voltage-dropping resistor sized so that the
applied voltage is 80 percent of rated lamp voltage.
Indicating lights must be designed so that relamping is performed from the
front of the MCC.
All special tools required, such as nonstandard wrenches, sockets, etc., used
to latch/unlatch, bolt/unbolt, equipment supplied under this specification,
must be provided with each MCC assembly.
Figure 9: Saudi Aramco Low Voltage MCC Nameplates, Wiring,

and Miscellaneous Equipment Requirements (From 16-SAMSS-503) (Cont'd)
Figure 10 shows the data schedule that is used to order low voltage switchracks and MCCs from
the manufacturer.

DATA SCHEDULE
FOR 16-SAMSS-503, LOW-VOLTAGE SWITCHRACKS
(600 VOLTS AND BELOW)
INFORMATION SUPPLIED BY BUYER
1. Buyer's Quotation Request/Purchase Order No. ________________________
2. Buyer's B.I./J.O. No. _____________________________________________
3. Buyer's Line Item No. _____________________________________________
4. Area Classification: ( ) Classified ( ) Unclassified
Class ______ Group(s) ______ Division ___
5. Enclosure Type: ( ) NEMA Type 4, 7 ( ) NEMA Type 4
( ) Other ___________________ (Specify)
6. Main Horizontal Bus Continuous Rating ___________ A (RMS) at:
( )50 deg C, (Covered)
( )70 deg C, (Uncovered)
7. Incoming Section Entry: ( ) Top, ( ) Bottom
No. of Access holes: ____________
8. Space Heater Supply; Voltage: __________________ V AC
Source: ( ) Buyer ( ) Vendor CPT
Maximum Surface Temperature of Heater Element deg C __________________
9. Canopy ( ) No ( ) Yes; Canopy Lighting ( ) Yes ( ) No
10. Enclosure Mounting and Arrangement: ( ) Single-Row
( ) Double-Row ( ) Front ( ) Back ( ) Front and Back
11. Incoming Feeder: ( ) Bus Duct ( ) Cable in Conduit
12. Size of Incoming Feeder: __________________
13. Cable Conductors per Phase: _______________
14. Control Power Voltage: ____________________
Approved: _____________________ Dwg. No. NT- __________________

Date: _____________________ Revision No. __________________
Sheet 1 of 1
Figure 10: Data Schedule for Low Voltage Switchracks
and MCCs (From 16-SAMSS-503)

Work Aid 1E: Medium Voltage MCC Ratings
Figure 11 shows medium voltage controller ratings.
1 Controllers that are rated for 630 amperes continuous are available from some manufacturers with interrupting
ratings up to 500 MVA at 4000 volts.
* Not extracted from NEMA standards.
Figure 11: Ratings for Class E2 (Fused) Medium Voltage Motor Controllers
(From SADP-P-116 and NEMA ICS 2-324)
The required interrupting capacity must be 350 MVA at 4800 volts.

Work Aid 1F: Medium Voltage MCC Requirements
The minimum technical requirements for medium-voltage (5 kV class), metal-enclosed indoor

MCCs are described in 16-SAMSS-506. The requirements of 16-SAMSS-506 apply to National
Electrical Manufacturers Association (NEMA) Class E-2 current-limiting fused controllers and all
control and auxiliary equipment that is assembled into MCCs.
Figure 12 shows Saudi Aramco medium voltage indoor MCC general requirements from 16-
SAMSS-506.
General Oil-immersed controllers are not acceptable for use in Saudi Aramco
Requirements installations.
Motor control assemblies must be suitable for continuous operation at
nameplate rating with cooling air surrounding the assembly enclosure within
the limits of 0oC and 40oC.
Designs and materials used in the control assemblies must have at least two
years of verifiable proven field service. The Vendor must supply a Users
List indicating User company name, installation site, date of installation, and
equipment characteristics similar to equipment quoted.
Figure 12: Saudi Aramco Medium Voltage MCC General Requirements

(From 16-SAMSS-506)
Figure 13 shows general construction and design requirements for medium voltage MCCs.

General Controllers must be of the metal enclosed type consisting of a free-standing,

Construction full-height structure with a maximum of two controllers per vertical section.
Requirements
Enclosures must be rigidly constructed to allow mounting pad level
variations of +/- 1/8 inch. Under these conditions, doors must open and
close smoothly and all mechanical interlocks must function properly.
Enclosures must be 2.28 m (90 in) nominal height.
If Vendor's standard is three-high construction, the top unit must be for
"FUTURE" or for auxiliary devices, as indicated on Engineering Drawings.
Grounded metal barriers must be provided to isolate each vertical section,
each compartment within a vertical section, high and low voltage
compartments, and main horizontal power bus compartment.
A corrosion-resistant coating over a suitably prepared surface must be
applied to the inside and outside of the cubicle.
Isolating shutters must be provided to automatically cover vertical bus when
a drawout component is moved to the withdrawn position on "FUTURE"
as well as active compartments.
All parts must be readily accessible for maintenance and inspection.
Power fuses and contactor must be mounted on a single drawout carriage
assembly.
Minimum The cubicle design must be NEMA Type 1 for installation in an
MCC environmentally controlled location.
Construction All ventilation openings must be suitably filtered or screened with stainless
and Design steel hardware cloth arranged to prevent the entrance of rodents.
Requirements
Figure 13: Saudi Aramco Medium Voltage MCC Construction

and Design (From 16-SAMSS-506)

Minimum All control devices must be selected for proper operation in the designated
MCC atmosphere without further protection.
Construction Enclosures must conform to NEMA ICS 6 "Enclosures for Industrial
and Design Controls and Systems" requirements for NEMA Type 1.
Requirements Enclosures must be of carbon steel sheet metal with supporting frame,
(Cont'd) designed for front access only, and suitable for back-to-wall or
back-to-back mounting.
Hinged and removable panels and doors must be provided with captive
hardware.
Self-tapping screws are not acceptable.
All unpainted hardware must be galvanized, stainless steel, or cadmium or
chromium plated.
Compartment doors must be double or full-length hinged.
Figure 13: Saudi Aramco Medium Voltage MCC Construction

and Design Requirements (From 16-SAMSS-506) (Cont'd)
Figure 14 shows Saudi Aramco medium voltage MCC enclosure and isolating panel requirements
from 16-SAMSS-506.
MCC Enclosures must conform to NEMA ICS 6 "Enclosures for Industrial

Enclosure Controls and Systems" requirements for NEMA Type 1.
Requirements Enclosures must be of carbon steel sheet metal with supporting frame,
designed for front access only, and suitable for back-to-wall or
back-to-back mounting.
Hinged and removable panels and doors must be provided with captive
hardware.
Self-tapping screws are not acceptable.
All unpainted hardware must be galvanized, stainless steel, or cadmium or
chromium plated.
Compartment doors must be double or full-length hinged.
Figure 14: Saudi Aramco Medium Voltage MCC Enclosure

and Isolating Panel Requirements (From 16-SAMSS-506)

Figure 15 shows Saudi Aramco medium voltage MCC bus and space heater requirements from
16-SAMSS-506.
Bus The entire length of the power bus must be individually insulated for rated
Requirements voltage.
Full height single units must be equipped with power bus bars and a wiring
trough extending the full cubicle width.
All power, ground, and wiring facilities must be arranged to facilitate future
additions.
All power and ground buses, including transition busing to other equipment,
must be constructed of bar material.
Cable is not acceptable for power or ground busing.
Power and ground buses must be full size and continuous throughout.
Tapered bus sizing is prohibited.
Bolted power bus connections must be provided with a minimum of 2 bolts,
nuts, and with either dished (conical) spring washers or flat washers and
split lockwashers.
Bus bar connection surfaces must be silver-plated or tin-plated.
Power bus insulation materials for bars and bar connections must be
flame-retardant, low-hygroscopic, and track-resistant throughout.
Bolted bus joints must be covered with removable insulating boots. Taping
of bus and bolted joints is not acceptable.
Bus phase arrangement must be 1, 2, 3, counting from front-to-back,
top-to-bottom, or left-to-right, as viewed from the main switching device
operating mechanism side.
Space Heaters Each vertical section must contain a thermostatically controlled space
heater.
Heating elements must have a voltage rating of approximately twice the
supply voltage for extended service life.
Heaters and associated circuits must be rated for continuous duty.
Each heater circuit must be provided with an externally operable
thermal-magnetic molded-case circuit breaker to serve as a disconnecting
and overcurrent protection device.
Figure 15: Saudi Aramco Medium Voltage MCC Bus

and Space Heater Requirements (From 16-SAMSS-506)

Figure 16 shows Saudi Aramco Medium voltage MCC nameplates, wiring, and miscellaneous
equipment requirements from 16-SAMSS-506.
Nameplates Nameplates must be attached to the controller group, individual doors, or

contactor as appropriate and must indicate the following:
1. Manufacturer's shop order number, date, and catalog
designation.
2. Horsepower rating of motor.
3. Interrupting rating of the controller.
4. Maximum continuous amperes.
5. Nominal voltage rating.
6. Control circuit voltage.
Separate nameplates suitably located must indicate:
1. Warning of operational instructions as required.
2. Identity of all relays, meters, and so forth.
3. Purchaser's assigned motor number if specified.
4. Foreign voltage when external sources are used.
Device nameplates must be provided for the identification of each controller
and auxiliary unit, indicating the circuit number and load served or
equipment contained within an auxiliary cubicle.
All panel mounted devices must be identified by escutcheon or nameplate
on the front of the panel and by nameplate on the rear of the panel adjacent
to the device terminals.
Protective relay nameplates must be provided to indicate protective
function, ANSI device number, and phase(s) which is/are monitored.
Device nameplates must be engraved laminated plastic with black 6.4 mm
(0.25 in) characters on a white 64 mm (2.5 in) by 25 mm (1 in) background
as a minimum. Device nameplates must be in the English language
according to American usage.
Figure 16: Saudi Aramco Medium Voltage MCC Nameplates, Wiring,

and Miscellaneous Equipment Requirements (From 16-SAMSS-506)

Nameplates Warning plates must be provided on each compartment door in which an

(Cont'd) external voltage source is terminated, reading: "CAUTION -THIS UNIT
CONTAINS AN EXTERNAL VOLTAGE SOURCE."
Auxiliary cubicles containing drawout or tilt-out potential transformers
supplying undervoltage relays must be provided with a warning nameplate
reading: "CAUTION - OPENING THIS COMPARTMENT TRIPS
UNDERVOLTAGE RELAYS."
Manual trip devices must be labelled: "Manual/Emergency Trip".
Warning nameplates must be engraved laminated plastic with
white characters on a red background. Warning nameplates
must be written in both Arabic and English.
Nameplates must be attached with stainless steel or brass screws except that
nameplates inside compartment may be attached with permanent adhesives.
Wiring Control and secondary conductors must be stranded copper 600 V NEC
Type SIS or THHN.
Minimum conductor size must be 2.5 sq mm (14 AWG).
Each wire must be identified with a thermoplastic, slip-on wire marker with
permanently printed characters. Snap-on and adhesive type markers are
prohibited.
All connection points between assembly control devices and field wiring
must be made with terminal blocks conforming to the requirements of 16-
SAMSS-506.
All connections between compartment control wiring and removable
assembly (truck) mounted devices must be by a single, self-aligning,
multi-contact, stab assembly. (When a stab assembly cannot be used, a
potted connector assembly must be used in the wiring harness.)
Miscellaneous Each controller must have both externally and internally operable control
Equipment devices.


Miscellaneous Pushbutton and selector switches must be of the heavy-duty oil-tight type
Equipment rated 10 A continuous at 600 V. Pushbutton control switches must be
(Cont'd) constructed to prevent accidental actuation.
Externally operable control devices must be of the hand-reset type for both
the overload relays and lockout relays.
An externally operable alternating current control circuit power switch must
be provided to be used as a control power disconnect and as a maintained
stop for both magnetically held and latched contactors.
Internally operable control devices must include a readily accessible
start/stop pushbutton to operate the main contactor for maintenance testing.
This device must be operable when the controller is in the test position.
An ammeter with a transfer switch and red and green "RUNNING" and
"STOPPED" indicating lights must be mounted clearly visibly on the
outermost cubicle door. The red and green indicating lights must be
supplied directly from "M" auxiliary contacts.
Hand-reset lockout relay operating coil circuit must be monitored by a
white indicating light located adjacent to the relay handle.
For motor feeders, an ammeter for motor space heaters must be mounted
clearly visible on the outermost cubicle door.
Indicating lights must be of the incandescent heavy-duty oil-tight type with
integral transformer or series voltage-dropping resistor sized so that the
applied voltage is 80 percent of rated lamp voltage.
Indicating lights must be designed so that relamping is performed from the
front of the MCC.
All special tools required, such as nonstandard wrenches, sockets, etc., used
to latch/unlatch, bolt/unbolt, equipment supplied under this specification,
must be provided with each MCC assembly.


WORK AID 2: REFERENCES FOR EVALUATING MOTOR CONTROL CENTER

INSTALLATION AND TESTING
Work Aid 2A: MCC Commissioning Electrical Test Values
1. Insulation resistance must not be less the fifty megohms.
a. Megger test voltages must be 1000 V dc in accordance with Saudi Aramco Pre-
Commissioning form P-000, Testing Guide Lines.
b. The insulation resistance (megger) test values must be greater than the
manufacturer's minimum value. If the manufacturer's minimum value is not
provided, the value of the insulation resistance should be greater than the rated
voltage + 1 kV in megohms. For example, a 600 V rated system must have a
measured insulation resistance that is greater than 1.6 megohms.
c. Do not megger solid state devices.
2. Contact resistance must be determine in microohms or millivolts. Values of contact

resistance in excess of 200 microohms and deviations of more than +/-20% must be
investigated. Technical data to evaluate the results of the contact resistance test can be
found in the circuit breaker manufacturer's technical manual or in the Saudi Aramco Pre-
Commissioning form, P-000, Testing Guide Lines.
3. A dc high-potential test is one in which the increase of applied voltage is controlled.

Measured currents are continuously observed for abnormalities with the intention of
stopping the test before breakdown occurs. The voltage that is used for the dc high-pot
test should be in accordance with the manufacturer's technical manual for the MCC. If a
manufacturer's technical manual is not available, then the Saudi Aramco Pre-
Commissioning Form, P-000, Testing Guide Lines, must be used. In accordance with P-
000, the high-pot test voltage is 9 kV for equipment that is rated 2.5 kV. The dc high-pot
test is conducted in two stages as follows:
a. A polarization index (PI) test is performed by applying an initial voltage step of

about one-third of the recommended maximum voltage. The initial voltage step
must be maintained at a constant level for 10 minutes. The PI is calculated by
dividing the one minute leakage current by the 10 minute leakage current. A PI
value of 2.0 or less must be investigated.
b. After the initial 10 minute test, the dc test voltage is increased in approximately 10
uniform steps. Each step should have a one minute duration. The voltage is
increased until the maximum recommended dc value is reached.

4. Minimum pickup current, trip times, and instantaneous pickup values of protective
equipment (e.g., relays) must be adjusted to engineer settings. Test values should fall
within manufacturer's published time-current characteristic tolerance band.
Work Aid 2B: Information, Formulas, and Tables for Use in Evaluating the Results of
Insulation Resistance (Megger) Tests
The results of all commissioning megger tests that are performed must be documented on the
appropriate Saudi Aramco pre-commissioning form.
The following are the types of megger tests that can be conducted:
• Short time or spot reading

• Time resistance
• Dielectric absorption ratio
When the dielectric absorption ratio megger test is performed, the polarization index can be
determined through use of the following equation:
Figure 17 provides insulation conditions for 60/30 second ratio results and for 10/1 minute ratio
results.
Figure 17: Dielectric Absorption Ratio Chart

Work Aid 2C: Information, Formulas, and Tables for Use in Evaluating the Results of
DC Hi-Pot Tests
The dc hi-pot test should be secured if one of the following situation occurs:
• The duration of the test has expired.

• A rapid rise in leakage current occurs.
• The polarization index < 1.
The following are the characteristics of a satisfactory dc hi-pot test:
• The leakage current gets smaller over time.

• The polarization index > 1.
• The leakage current increases on a straight line as voltage is increased. No "knee"
is noticeable in the leakage current curve.
An example of dc hi-pot test data is shown in Figure 18. Figure 18 also shows both good and bad
insulation test data.
Figure 18: Example of DC Hi-Pot Test (Good and Bad Insulation)

Work Aid 2D: Saudi Aramco Pre-Commissioning Form
Figures 19 shows the Saudi Aramco Pre-Commissioning Form, P-018, Motor Control Centers,
which provides a field installation checklist for MCC installations. The pre-commissioning form
has a broad checklist of visual and mechanical inspections, as well as the listed electrical and tests
that are required for MCC installations. Space is also provided on the form for test data.

Figure 19: Saudi Aramco Pre-Commissioning Form, P-018, Motor Control Centers


Motor Control Centers (Cont'd)









Work Aid 2E: Excerpts from GI 2.710
The following is an excerpt from GI 2.710, New Construction Check List Example, that
illustrates the overall checklist and sign-off for major pieces of electrical equipment.
3. Electrical Equipment
All substations, power

cable, electrical equipment, Construction Agency
including lighting and
wiring, to be checked for
proper application,
operation, and grounds.
Distribution panels,
switches properly identified,
and all energization
certificate requests signed.
Power Distribution Dept.
Project Inspection
Commissioning (Note 1)
Figure 20 shows an excerpt from GI 2.710, General Instruction Manual, that illustrates the
inspections and tests that should be performed on major pieces of electrical equipment prior to the
turnover of a facility.

Figure 20: GI 2.710 Excerpt

Figure 20: GI 2.710 Excerpt (Cont'd)

Figure 20: GI 2.710 Excerpt (Cont'd)

GLOSSARY
dielectric absorption The ratio of two timed insulation resistance readings (such as a
ratio 60-second reading that is divided by a 30-second reading).
polarization index The ratio is a ten-minute insulation resistance reading that is divided
by a one-minute insulation resistance reading.

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